Vaporizable material insert with internal airflow pathway

ABSTRACT

Various embodiments of a system for generating an inhalable aerosol are described. The system can include a vaporizable material insert configured to be inserted into a compartment of a vaporizer body of a vaporizer device. In some embodiments, the insert includes a housing defining an inner chamber having a first compartment that contains a vaporizable material and a second compartment defining an insert airflow pathway. The insert airflow pathway can be positioned upstream from a device airflow pathway of the vaporizer body, and the inhalable aerosol can be formed in the insert airflow pathway. As such, the inhalable aerosol can be prevented from contacting and contaminating the vaporizer body during use. Related systems, methods, and articles of manufacture are also described.

TECHNICAL FIELD

The subject matter described herein relates to various embodiments of a vaporizable material insert for use with a vaporizer device.

BACKGROUND

Vaporizer devices, which can also be referred to as vaporizers, electronic vaporizer devices, or e-vaporizer devices, can be used for delivery of an aerosol (for example, a vapor-phase and/or condensed-phase material suspended in a stationary or moving mass of air or some other gas carrier) containing one or more active ingredients by inhalation of the aerosol by a user of the vaporizing device. For example, electronic nicotine delivery systems (ENDS) include a class of vaporizer devices that are battery powered and that can be used to simulate the experience of smoking. Vaporizers are gaining increasing popularity both for prescriptive medical use, in delivering medicaments, and for consumption of tobacco, nicotine, and other plant-based materials. Vaporizer devices can be portable, self-contained, and/or convenient for use.

In use of a vaporizer device, the user inhales an aerosol, colloquially referred to as “vapor,” which can be generated by a heating element that vaporizes a vaporizable material, for example, by causing the vaporizable material to transition at least partially to a gas phase. The vaporizable material may be a liquid, a solution, a solid, a paste, a wax, and/or any other form compatible for use with a specific vaporizer device. Moreover, the vaporizable material used with a vaporizer can be provided within a vaporizer cartridge, which may be a separable part of the vaporizer device that contains the vaporizable material and having an outlet (e.g., a mouthpiece) for delivering the aerosol generated by the vaporization of the vaporizable material to a user.

To receive the inhalable aerosol generated by a vaporizer device, a user may, in certain examples, activate the vaporizer device by taking a puff, by pressing a button, and/or by some other approach. A puff as used herein can refer to inhalation by the user in a manner that causes a volume of air to be drawn into the vaporizer device such that the inhalable aerosol is generated when the vaporized vaporizable material is combined with the volume of air.

An approach by which a vaporizer device generates an inhalable aerosol from a vaporizable material involves heating the vaporizable material in a vaporization chamber (e.g., a heater chamber) to cause the vaporizable material to be converted to the gas (or vapor) phase. A vaporization chamber can refer to an area or volume in the vaporizer device within which a heat source (for example, a conductive, convective, and/or radiative heat source) causes heating of a vaporizable material to produce a mixture of air and vaporized material to form a vapor for inhalation of the vaporizable material by a user of the vaporization device.

In some embodiments, vaporizer cartridges configured to heat solid vaporizable material (e.g. plant material such as tobacco leaves and/or parts of tobacco leaves) can require higher temperatures for inner tobacco regions to reach a minimum required temperature for vaporization. As a result, burning the solid vaporizable material at these high peak temperatures can produce toxic byproducts (e.g., chemical elements or chemical compounds).

Vaporizer devices can be categorized into two classes, those that heat through conduction and those that heat through convection. For example, conduction-based vaporizer devices may be configured to vaporize liquid vaporizable material using a heating element contacting the liquid vaporizable material. As such, the liquid vaporizable material may contaminate the heating element, which can compromise performance of the vaporizer device. Some vaporizers may incorporate the heating element into the disposable part of the vaporizer device (e.g., the cartridge), such that the heating element may be replaced with each new cartridge and thereby limit, but not eliminate, heating element contamination. However, this can increase manufacturing labor and costs associated with the disposable. Furthermore, uniform heating of the vaporizable material in current conduction-based vaporizers may be difficult to achieve due to the low thermal conductivity of certain vaporizable materials (e.g., plant materials, such as tobacco).

Some issues with current vaporizer devices include contamination of the reusable portion of the vaporizer device as a result of vaporizing the vaporizable material and/or contact of the inhalable aerosol with the reusable portion of the vaporizer device, such as before inhalation by a user. Such contamination can result in decreased efficiency and effectiveness of the vaporizer device, as well as require periodic maintenance and/or cleaning of the vaporizer device, which can be neglected by and undesirable to users.

SUMMARY

Aspects of the current subject matter can include various embodiments of a system for generating an inhalable aerosol. In one aspect, the system can include an insert including a housing defining an inner chamber. The inner chamber can include a first compartment configured to contain a non-liquid vaporizable material, and the non-liquid vaporizable material can form a part of the inhalable aerosol as a result of being heated. The inner chamber can also include a second compartment that is separate from the first compartment of the inner chamber and defines a first insert airflow pathway. The second compartment can extend between an inlet and an outlet of the housing. The second compartment can also be configured to allow formation of the inhalable aerosol therealong and delivery of the inhalable aerosol through the outlet for inhalation by a user. The system can also include a vaporizer body including a receptacle configured to receive the insert and a device airflow pathway that extends into the receptacle. The device airflow pathway can be upstream from and in fluid communication with the first insert airflow pathway. The vaporizer body can also include a heating element configured to heat the insert positioned in the compartment to generate the inhalable aerosol.

In some variations one or more of the following features can optionally be included in any feasible combination. The outlet can be positioned along a mouthpiece of the insert. The inlet can be positioned along a first end of the insert, and the first end can be opposed to a second end including the mouthpiece. The first compartment and the second compartment can extend approximately parallel to each other. In some embodiments, the inner chamber can further include a third compartment configured to contain the non-liquid vaporizable material, and the second compartment can be positioned between the first compartment and the third compartment. In some embodiments, the inner chamber can further include a third compartment configured to define a second insert airflow pathway that is downstream from the device airflow pathway, and the first compartment can be positioned between the second compartment and the third compartment.

In some embodiments, the housing can include a thermally conductive material. The thermally conductive material can include an aluminum foil. In some embodiments, the housing can include a paper material. The non-liquid vaporizable material can include a plant material and/or a plant material based product. The non-liquid vaporizable material can include a tobacco leaf and/or a reconstituted tobacco.

In another aspect, various embodiments of an insert are described that are configured to be inserted into a compartment of a vaporizer device. The insert can include a housing defining an inner chamber. The inner chamber can include a first compartment configured to contain a non-liquid vaporizable material, and the non-liquid vaporizable material can form a part of the inhalable aerosol as a result of being heated. The inner chamber can also include a second compartment that is separate from the first compartment of the inner chamber and defines a first insert airflow pathway. The second compartment can extend between an inlet and an outlet of the housing. The second compartment can be configured to allow formation of the inhalable aerosol therealong and delivery of the inhalable aerosol through the outlet for inhalation by a user.

In some variations one or more of the following features can optionally be included in any feasible combination. The outlet can be positioned along a mouthpiece of the insert. The inlet can be positioned along a first end of the insert, and the first end can be opposed to a second end including the mouthpiece. The first compartment and the second compartment can extend approximately parallel to each other. In some embodiments, the inner chamber can further include a third compartment configured to contain the non-liquid vaporizable material, and the second compartment can be positioned between the first compartment and the third compartment. In some embodiments, the inner chamber can further include a third compartment configured to define a second insert airflow pathway that is downstream from the device airflow pathway, and the first compartment can be positioned between the second compartment and the third compartment.

In some embodiments, the housing can include a thermally conductive material. The thermally conductive material can include aluminum foil. The housing can include a paper material. The non-liquid vaporizable material can include a plant material and/or a plant material based product. The non-liquid vaporizable material can include a tobacco leaf and/or a reconstituted tobacco.

In another interrelated aspect of the current subject matter, a method includes generating an inhalable aerosol for inhalation by a user. In some embodiments, the method includes receiving an insert into a receptacle of a vaporizer device. The insert can include a housing defining an inner chamber, and the inner chamber can include a first compartment configured to contain a non-liquid vaporizable material. The non-liquid vaporizable material can form a part of the inhalable aerosol as a result of being heated. The inner chamber can also include a second compartment that is separate from the first part of the inner chamber and defines a first insert airflow pathway. The second compartment can extend between an inlet and an outlet of the housing. The second compartment can be configured to allow formation of the inhalable aerosol therealong and delivery of the inhalable aerosol through the outlet for inhalation by a user. The method can further include activating a heating element configured to heat the vaporizable material and forming, as a result of the activating and heating of the vaporizable material, the inhalable aerosol along the second compartment for delivery of the inhalable aerosol through the outlet of the housing for inhalation by the user.

In some variations one or more of the following features can optionally be included in any feasible combination. The vaporizer body can include a receptacle configured to receive the insert and a device airflow pathway that extends into the receptacle. The device airflow pathway can be upstream from and in fluid communication with the insert airflow channel. The vaporizer body can further include a heating element configured to heat the insert positioned in the compartment to generate the inhalable aerosol. The first compartment and the second compartment can extend approximately parallel to each other. The inner chamber can further include a third compartment configured to contain the non-liquid vaporizable material, and the second compartment can be positioned between the first compartment and the third compartment. The inner chamber can further include a third compartment configured to define a second insert airflow pathway that is downstream from the device airflow pathway, and the first compartment can be positioned between the second compartment and the third compartment.

In some embodiments, the housing can include a thermally conductive material. The thermally conductive material can include aluminum foil. The housing can include a paper material. The non-liquid vaporizable material can include a plant material and/or a plant material based product. The non-liquid vaporizable material can include a tobacco leaf and/or a reconstituted tobacco.

The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings:

FIG. 1 is a block diagram of a vaporizer device consistent with implementations of the current subject matter;

FIG. 2A illustrates a top perspective view of an embodiment of an insert;

FIG. 2B illustrates an end perspective view of the insert of FIG. 2A;

FIG. 2C illustrates an end section view of the insert of FIG. 2A showing an inner chamber of the insert;

FIG. 3A illustrates a side cross section view of an embodiment of an insert being inserted in a vaporizable material insert receptacle of an embodiment of a vaporizer body;

FIG. 3B illustrates a side cross section view of the insert of FIG. 3A inserted in the vaporizable material insert receptacle of the vaporizer body;

FIG. 4A illustrates a side perspective view of at least a part of an embodiment of the inner chamber of FIG. 2C; and

FIG. 4B illustrates a side perspective view of at least a part of another embodiment of the inner chamber of FIG. 2C.

When practical, similar reference numbers denote similar structures, features, or elements.

DETAILED DESCRIPTION

Implementations of the current subject matter include methods, apparatuses, articles of manufacture, and systems relating to vaporization of one or more vaporizable materials for inhalation by a user. Example implementations include vaporizer devices and systems including vaporizer devices. The term “vaporizer device” as used in the following description and claims refers to any of a self-contained apparatus, an apparatus that includes two or more separable parts (for example, a vaporizer body that includes a battery and other hardware, and an insert that includes a vaporizable material), and/or the like. A “vaporizer system,” as used herein, can include one or more components, such as a vaporizer device. Examples of vaporizer devices consistent with implementations of the current subject matter include electronic vaporizers, electronic nicotine delivery systems (ENDS), and/or the like. In general, such vaporizer devices are hand-held devices that heat (such as by convection, conduction, radiation, and/or some combination thereof) a vaporizable material to provide an inhalable dose of the material.

The vaporizable material used with a vaporizer device may optionally be provided within a vaporizable material insert (e.g., a part of the vaporizer device that contains the vaporizable material) which can be disposable such that a new vaporizable material insert containing additional vaporizable material of a same or different type can be used. A vaporizer device can be an insert-using vaporizer device or a multi-use vaporizer device capable of use with or without an insert. For example, embodiments of vaporizable material inserts can be at least partly made of a non-liquid vaporizable material. As such, some embodiments of the vaporizer body can be configured to receive a vaporizable material insert that includes one or more vaporizable materials for heating and forming an inhalable aerosol, as will be described in greater detail below. In some embodiments, the vaporizer body can include a heating chamber or compartment (e.g., a vaporizable material insert receptacle) configured to receive the vaporizable material insert directly therein and heat the vaporizable material insert for forming an inhalable aerosol.

Various vaporizable material inserts are described herein that include a housing defining an inner chamber. The inner chamber can include at least a first compartment and a second compartment that is separate from the first compartment. For example, the first compartment can contain non-liquid vaporizable material for heating and forming the inhalable aerosol. The second compartment of the inner chamber can include an insert airflow pathway that extends through the vaporizable material insert and prevents the inhalable aerosol from contacting the vaporizer body, thereby reducing or preventing contamination of the vaporizer body by the inhalable aerosol. This can require less cleaning and/or provide improved functioning of the vaporizer body, which can result in improved user experience of the vaporizer device.

The vaporizer device can be configured for use with a variety of non-liquid vaporizable materials (e.g., a paste, a wax, a solid, a plant material, and/or the like). A non-liquid vaporizable material can include a plant material that emits some part of the plant material as the vaporizable material (for example, some part of the plant material remains as waste after the material is vaporized for inhalation by a user) or optionally can be a solid form of the vaporizable material itself, such that all of the solid material can eventually be vaporized for inhalation.

FIG. 1 depicts a block diagram illustrating an example of a vaporizer device 100 consistent with implementations of the current subject matter. Referring to FIG. 1 , the vaporizer device 100 can include a power source 112 (for example, a battery, which can be a rechargeable battery), and a controller 104 (for example, a processor, circuitry, etc. capable of executing logic) for controlling delivery of heat from a heating element 150 to cause a vaporizable material 102 of a vaporizable material insert 122 to be converted from a condensed form (such as a solid, a liquid, a solution, a suspension, a part of an at least partially unprocessed plant material, etc.) to the gas phase. The controller 104 can be part of one or more printed circuit boards (PCBs) consistent with certain implementations of the current subject matter.

After conversion of the vaporizable material 102 to the gas phase, at least some of the vaporizable material 102 in the gas phase can condense to form particulate matter in at least a partial local equilibrium with the gas phase as part of an aerosol, which can form some or all of an inhalable dose provided by the vaporizer device 100 during a user's puff or draw on the vaporizer device 100. It should be appreciated that the interplay between gas and condensed phases in an aerosol generated by a vaporizer device 100 can be complex and dynamic, due to factors such as ambient temperature, relative humidity, chemistry, flow conditions in airflow paths (both inside the vaporizer and in the airways of a human or other animal), and/or mixing of the vaporizable material 102 in the gas phase or in the aerosol phase with other air streams, which can affect one or more physical parameters of an aerosol. In some vaporizer devices, and particularly for vaporizer devices configured for delivery of volatile vaporizable materials, the inhalable dose can exist predominantly in the gas phase (for example, formation of condensed phase particles can be very limited).

The heating element 150 can include one or more of a conductive heater, a radiative heater, and/or a convective heater. One type of heating element is a resistive heating element, which can include a material (such as a metal or alloy, for example a nickel-chromium alloy, or a non-metallic resistor) configured to dissipate electrical power in the form of heat when electrical current is passed through one or more resistive segments of the heating element. In some implementations of the current subject matter, the heating element 150 (e.g., a resistive heating element and/or the like) is configured to generate heat for vaporizing the vaporizable material 102 to generate an inhalable dose of the vaporizable material 102. As noted, the vaporizable material 102 may be a liquid or non-liquid (or combination of both liquid and non-liquid). For example, the heating element 150 may be wrapped around, positioned within, integrated into a bulk shape of, pressed into thermal contact with, or otherwise arranged to deliver heat to the vaporizable material 102 to be vaporized for subsequent inhalation by a user in a gas and/or a condensed (for example, aerosol particles or droplets) phase.

In some embodiments, the vaporizable material 102 may be a non-liquid vaporizable material including, for example, a solid-phase material (such as a gel, a wax, or the like) or plant material (e.g., tobacco leaves and/or parts of tobacco leaves). Where the vaporizable material 102 is a non-liquid vaporizable material, the heating element 150 can be part of, or otherwise incorporated into or in thermal contact with, the walls of a heating chamber or compartment (e.g., vaporizable material insert receptacle 118) into which the vaporizable material insert 122 is placed. Alternatively, the heating element 150 can be used to heat air passing through or past the vaporizable material insert 122, to cause convective heating of the vaporizable material 102 of the vaporizable material insert 122. In some embodiments, the heating element 150 can be a part of the vaporizer body 110 (e.g., part of the durable or reusable part of the vaporizer 100), as shown in FIG. 1 .

The heating element 150 can be activated in association with a user puffing (e.g., drawing, inhaling, etc.) on an end and/or mouthpiece 157 of the vaporizer device 100 to cause air to flow from an air inlet, along an airflow path for assisting with forming an inhalable aerosol that can be delivered out through an air outlet in the mouthpiece 157 (e.g., located along the vaporizable material insert 122). Incoming air moving along the airflow path moves over or through the heating element 150 and/or vaporizable material 102 where vaporizable material 102 in the gas phase is entrained into the air. The heating element 150 can be activated via the controller 104, which can optionally be a part of the vaporizer body 110 as discussed herein, causing current to pass from the power source 112 through a circuit including the heating element 150, which can be part of the vaporizer body 110. As noted herein, the entrained vaporizable material 102 in the gas phase can condense as it passes through the remainder of the airflow path such that an inhalable dose of the vaporizable material 102 in an aerosol form can be delivered from the air outlet (for example, the mouthpiece) for inhalation by a user.

Activation of the heating element 150 can be caused by automatic detection of a puff based on one or more signals generated by one or more sensor(s) 113. The sensor 113 and the signals generated by the sensor 113 can include one or more of: a pressure sensor or sensors disposed to detect pressure along the airflow path relative to ambient pressure (or optionally to measure changes in absolute pressure), a motion sensor or sensors (for example, an accelerometer) of the vaporizer device 100, a flow sensor or sensors of the vaporizer device 100, a capacitive lip sensor of the vaporizer device 100, detection of interaction of a user with the vaporizer device 100 via one or more input devices 116 (for example, buttons or other tactile control devices of the vaporizer device 100), receipt of signals from a computing device in communication with the vaporizer device 100, and/or via other approaches for determining that a puff is occurring or imminent.

As discussed herein, the vaporizer device 100 consistent with implementations of the current subject matter can be configured to connect (such as, for example, wirelessly or via a wired connection) to a computing device (or optionally two or more devices) in communication with the vaporizer device 100. To this end, the controller 104 can include communication hardware 105. The controller 104 can also include a memory 108. The communication hardware 105 can include firmware and/or can be controlled by software for executing one or more cryptographic protocols for the communication.

A computing device can be a component of a vaporizer system that also includes the vaporizer device 100, and can include its own hardware for communication, which can establish a wireless communication channel with the communication hardware 105 of the vaporizer device 100. For example, a computing device used as part of a vaporizer system can include a general-purpose computing device (such as a smartphone, a tablet, a personal computer, some other portable device such as a smartwatch, or the like) that executes software to produce a user interface for enabling a user to interact with the vaporizer device 100. In other implementations of the current subject matter, such a device used as part of a vaporizer system can be a dedicated piece of hardware such as a remote control or other wireless or wired device having one or more physical or soft (e.g., configurable on a screen or other display device and selectable via user interaction with a touch-sensitive screen or some other input device like a mouse, pointer, trackball, cursor buttons, or the like) interface controls. The vaporizer device 100 can also include one or more outputs 117 or devices for providing information to the user. For example, the outputs 117 can include one or more light emitting diodes (LEDs) configured to provide feedback to a user based on a status and/or mode of operation of the vaporizer device 100.

In the example in which a computing device provides signals related to activation of the heating element, or in other examples of coupling of a computing device with the vaporizer device 100 for implementation of various control or other functions, the computing device executes one or more computer instruction sets to provide a user interface and underlying data handling. In one example, detection by the computing device of user interaction with one or more user interface elements can cause the computing device to signal the vaporizer device 100 to activate the heating element to reach an operating temperature for creation of an inhalable dose of vapor/aerosol. Other functions of the vaporizer device 100 can be controlled by interaction of a user with a user interface on a computing device in communication with the vaporizer device 100.

The temperature of the heating element 150 of the vaporizer device 100 can depend on a number of factors, including an amount of electrical power delivered to the heating element 150 and/or a duty cycle at which the electrical power is delivered, conductive heat transfer to other parts of the vaporizer device 100 and/or to the environment, latent heat losses due to vaporization of the vaporizable material 102, and convective heat losses due to airflow (e.g., air moving across the heating element 150 when a user inhales on the vaporizer device 100). As noted herein, to reliably activate the heating element 150 or heat the heating element 150 to a desired temperature, the vaporizer device 100 may, in some implementations of the current subject matter, make use of signals from the sensor 113 (for example, a pressure sensor) to determine when a user is inhaling. The sensor 113 can be positioned in the airflow path and/or can be connected (for example, by a passageway or other path) to an airflow path containing an inlet for air to enter the vaporizer device 100 and an outlet via which the user inhales the resulting vapor and/or aerosol such that the sensor 113 experiences changes (for example, pressure changes) concurrently with air passing through the vaporizer device 100 from the air inlet to the air outlet. In some implementations of the current subject matter, the heating element 150 can be activated in association with a user's puff, for example by automatic detection of the puff, or by the sensor 113 detecting a change (such as a pressure change) in the airflow path.

The sensor 113 can be positioned on or coupled to (e.g., electrically or electronically connected, either physically or via a wireless connection) the controller 104 (for example, a printed circuit board assembly or other type of circuit board). To take measurements accurately and maintain durability of the vaporizer device 100, it can be beneficial to provide a seal resilient enough to separate an airflow path from other parts of the vaporizer device 100. The seal, which can be a gasket, can be configured to at least partially surround the sensor 113 such that connections of the sensor 113 to the internal circuitry of the vaporizer device 100 are separated from a part of the sensor 113 exposed to the airflow path. Such arrangements of the seal in the vaporizer device 100 can be helpful in mitigating against potentially disruptive impacts on vaporizer components resulting from interactions with environmental factors such as water in the vapor or liquid phases and/or to reduce the escape of air from the designated airflow path in the vaporizer device 100. Unwanted air, liquid or other fluid passing and/or contacting circuitry of the vaporizer device 100 can cause various unwanted effects, such as altered pressure readings, and/or can result in the buildup of unwanted material, such as moisture, errant portions of the vaporizable material 102, etc., in parts of the vaporizer device 100 where they can result in poor pressure signal, degradation of the sensor 113 or other components, and/or a shorter life of the vaporizer device 100. Leaks in the seal can also result in a user inhaling air that has passed over parts of the vaporizer device 100 containing, or constructed of, materials that may not be desirable to be inhaled.

In some implementations, the vaporizable material insert 122 can be configured for insertion in the vaporizable material insert receptacle 118, and can have a non-circular cross section transverse to the axis along which the vaporizable material insert 122 is inserted into the vaporizable material insert receptacle 118. For example, the non-circular cross section can be approximately rectangular, approximately elliptical (e.g., have an approximately oval shape), non-rectangular but with two sets of parallel or approximately parallel opposing sides (e.g., having a parallelogram-like shape), or other shapes having rotational symmetry of at least order two. In this context, approximate shape indicates that a basic likeness to the described shape is apparent, but that sides of the shape in question need not be completely linear and vertices need not be completely sharp. Rounding of both or either of the edges or the vertices of the cross-sectional shape is contemplated in the description of any non-circular cross section referred to herein.

In some embodiments, as shown in FIG. 1 , the vaporizable material insert 122 can include a jacket or housing 152 (e.g., made out of a biodegradable material) that defines an inner chamber 153. As will be described in greater detail below, the inner chamber 153 can include at least two compartments, such as a first compartment that contains the vaporizable material 102 and a second compartment that defines an insert airflow pathway 155 extending through the vaporizable material insert 122.

When a user puffs on the vaporizer device 100, air can be drawn into and through at least a part of the vaporizer material insert 122 (e.g., into and along the insert airflow pathway 155) and out through an outlet (e.g., along a mouthpiece 157) of the vaporizable material insert 122 for delivery of the inhalable aerosol to a user, as will be described in greater detail below.

As discussed above, the vaporizer device 100 can be configured to heat a non-liquid vaporizable material 102 including, for example, a plant material (e.g., tobacco leaves), a plant material based product (e.g., reconstituted tobacco) and/or the like. As such, some embodiments of the vaporizable material insert receptacle 118 can be configured to receive and heat the vaporizable material insert 122 including non-liquid vaporizable material 102, such as for forming inhalable aerosol. For example, the vaporizable material insert receptacle 118 can include all or part of the heating element 150 (e.g., a heating coil, heating plate, etc.) that is configured to heat the vaporizable material insert 122 received in the vaporizable material insert receptacle 118. Furthermore, the vaporizable material insert receptacle 118 can be configured to receive and heat one or more of a variety of vaporizable material inserts 122, including embodiments of the vaporizable material inserts 122 described herein.

FIGS. 2A-2C illustrate an embodiment of the vaporizable material insert 122 including a housing 152 that forms an inner chamber 153. As shown in FIG. 2C the inner chamber 153 can be divided into at least two separate compartments. For example, at least part of one or more compartments can be defined by a part of the housing 152. In some embodiments, the housing 152 can define at least one side of at least one of the compartments. Each compartment can provide a separate and at least partly confined volume within the inner chamber 153. For example, some embodiments of the inner chamber 153 can include a first compartment 260 that contains vaporizable material 102 and a second compartment 262 that defines the insert airflow pathway 155.

As shown in FIG. 2C, the inner chamber 153 of the vaporizable material insert 122 can include more than two separate compartments, such as a third compartment 263 that may define another insert airflow pathway 155. In some embodiments, the first chamber 260 including the vaporizable material 102 can be positioned between the second and third compartments 262 and 263 that define inner airflow pathways 155, as shown in FIG. 2C. The inner chamber 153 can include a variety of compartment configurations that are within the scope of this disclosure.

In some embodiments, one or more compartments of the vaporizable material insert 122 can be defined by one or more layers of a vaporizable material 102 (e.g., reconstituted tobacco) wrapped in a paper material. In some embodiments, an outer surface of the vaporizable material insert 122, such as an outer surface of the housing 152, can be wrapped in and/or include a material (e.g., cigar paper) that is thicker than the paper material. In some embodiments, an outer surface of the vaporizable material insert 122 can be wrapped in and/or include a metal foil. In some embodiments, the vaporizable material 102 of the vaporizable material insert 122 can include compressed tobacco that is wrapped in cigarette paper. In some embodiments, the vaporizable material insert 122 can include at least one compartment including one or more pouches containing strips of vaporizable material (e.g., a plurality of strips of reconstituted tobacco wrapped up together), ground vaporizable material wrapped in a paper material, and/or loose leaf vaporizable material wrapped in paper material. In some embodiments, a filter material can be included in or adjacent to the mouthpiece 157. The filter material can be configured to form part of one or more of the airflow pathway(s) that extend through the vaporizable material insert 122.

As shown in FIG. 2B, the housing 152 can include two holes or first and second inlets 270 a and 270 b, respectively, along a first end 290 of the vaporizable material insert 122. For example, the first end 290 can be at an end opposing a second end 292 that includes the mouthpiece 157 and outlet 272, as shown in FIG. 2B. In some embodiments, one of the insert airflow pathways 155 can extend between the first inlet 270 a and the outlet 272 and the other insert airflow pathway 155 can extend between the second inlet 270 b and the outlet 272. As such, the insert airflow pathways 155 can merge upstream from the outlet 272 and/or within the mouthpiece 157 prior to being inhaled by a user.

In some embodiments, inhalable aerosol can be formed along one or more insert airflow pathways 155, such as due to heating of the vaporizable material 102 in the first compartment 260 and thereby converting at least some of the vaporizable material 102 to a gas phase that can become entrained into the airflow traveling along the one or more insert airflow pathways 155. The inhalable aerosol formed in the vaporizable material insert 122 can flow out of the vaporizable material insert 122 through the outlet 272 along the mouthpiece 157 (e.g., for inhalation by a user) without contacting the vaporizer body 110. This can reduce or prevent contamination of the vaporizer body 110 as a result of contact with the inhalable aerosol.

FIGS. 3A and 3B illustrate an embodiment of the vaporizer body 110 receiving an embodiment of the vaporizable material insert 122, such as for heating the vaporizable material insert 122 to form an inhalable aerosol. As shown in FIG. 3A, the vaporizer body 110 can include a device airflow pathway 280 that extends between an outer surface of the vaporizer body 110 and the vaporizable material insert receptacle 118. As shown in FIG. at least one device airflow pathway 280 can be in fluid communication with a distal end of the vaporizable material insert receptacle 118. For example, airflow flowing into the vaporizable material insert receptacle 118 from the vaporizable material insert pathway 280 can be directed approximately to the first end 290 of the vaporizable material insert 122. The airflow can then be directed into and along the one or more insert airflow pathways 155 of the vaporizable material insert 122 for formation of the inhalable aerosol.

In some embodiments, the vaporizer body 110 can include a heating element 150 that extends along one or more sides of the vaporizable material insert receptacle 118, as shown in FIG. 3A. As such, when the vaporizable material insert 122 is positioned within the vaporizable material insert receptacle 118 the heating element 150 can be positioned adjacent to and/or in contact with the vaporizable material insert 122. For example, the heating element 150 can extend along and/or be adjacent to one or more sides of the vaporizable material insert 122 when the vaporizable material insert 122 is positioned in the vaporizable material insert receptacle 118, as shown in FIG. 3B.

In some embodiments, the vaporizable material insert receptacle 118 can include all or part of the heating element 150 (e.g., a heating coil, etc.) that is configured to heat the vaporizable material insert 122 received in the vaporizable material insert receptacle 118. In some embodiments, the vaporizable material insert 122 can include a part of the heating element 150, such as include a thermally conductive material (e.g., aluminum). Various embodiments of the heating element 150 for heating various embodiments of the vaporizable material insert 122 to form inhalable aerosol are within the scope of this disclosure.

As shown in FIG. 3B, when a user draws in air or puffs on the mouthpiece 157, airflow can travel into and along the device airflow pathway 280 and the insert airflow pathway 155. For example, the insert airflow pathway 155 can be downstream from and in fluid communication with the device airflow pathway 280, such as when the vaporizable material insert 122 is positioned within the vaporizable material insert receptacle 118. As such, when a user draws in air or puffs on the vaporizer device 100, airflow can be drawn into and flow along the device airflow pathway 280 and then be drawn into (e.g., through the first inlet 270 a and/or the second inlet 270 b) and flow along the at least one insert airflow pathway 155. While traveling along the insert airflow pathway 155, at least some of the airflow can form into inhalable aerosol, as discussed above. The inhalable aerosol can be drawn out of the vaporizable material insert 122 through the outlet 272 along the mouthpiece 157, such as for inhalation by a user. As such, the inhalable aerosol is formed and flows within the vaporizable material insert 122 and does not contact the vaporizer body 110. For example, when the inhalable aerosol exits the vaporizable material insert 122, the inhalable aerosol is allowed to flow out of the outlet 272 of the mouthpiece 157, such as for inhalation by a user.

After the vaporizable material insert 122 has been used, such as after the vaporizable material 102 has been depleted, the remaining parts of the vaporizable material insert 122 (e.g., the housing 152) can be removed from the vaporizable material insert receptacle 118 and disposed of. A new vaporizable material insert 122 can replace the used vaporizable material insert 122 within the vaporizable material insert receptacle 118 to allow for reusable use of the vaporizer body 110.

As discussed above, embodiments of the vaporizable material insert 122 disclosed herein include at least one insert airflow pathway 155 that can extend downstream from the device airflow pathway 280 such that the inhalable aerosol formed in the insert airflow pathway 155 does not come into contact with the vaporizer body 110. This can reduce or prevent contamination of the vaporizer body 110, which can result in improved performance and less cleaning and maintenance of the vaporizer body 110.

The vaporizable material insert receptacle 118, including the heating element 150, can include various features and shapes for containing and heating the vaporizable material insert 122, such as to provide close contact between one or more walls of the vaporizable material insert 122 and the vaporizable material insert receptacle 118 to achieve efficient and effective heating of the vaporizable material insert 122. The vaporizable material insert receptacle 118 can include a variety of shapes and sizes for effectively accepting the vaporizable material insert 122 for heating and forming an inhalable aerosol. For example, the vaporizable material insert receptacle 118 can provide a sliding or friction fit along at least one side of the vaporizable material insert 122, such as for ensuring efficient and effective heating of the vaporizable material insert 122 and securing placement of the vaporizable material insert 122 in the vaporizable material insert receptacle 118.

As shown in FIGS. 2A and 2B, the vaporizable material 102 may be a non-liquid vaporizable material including, for example, a plant material (e.g., tobacco leaves), a plant material-based product (e.g., reconstituted tobacco), and/or the like. In some embodiments, the vaporizable material may include a sponge that is at least partly saturated with a liquid vaporizable material 102. In some embodiments, the housing 260 can be made of a material that prevents passage of air through the material.

FIGS. 4A and 4B illustrate example embodiments of the inner chamber 153 including various configurations of the first compartment 260, second compartment 262, and third compartment 263. As shown in FIG. 4A, the first compartment 260 and the third compartment 263 can contain vaporizable material 102 and the second compartment 262 can define the insert airflow pathway 155 and be positioned between the first compartment 260 and third compartment 263. The first compartment 260, second compartment 262, and third compartment 263 can extend approximately parallel to each other, such as along a length extending between the first end 290 and the second end 292 of the vaporizable material insert 122. In some embodiments, the first compartment 260, second compartment 262, and third compartment 26 can extend approximately along a same plane and collectively form a square or rectangular shape, as shown in FIGS. 4A and 4B. Other shapes and configurations of the inner chamber 153 are within the scope of this disclosure.

As shown in FIG. 4B, the second compartment 262 can define a first insert airflow pathway 155 and the third compartment 263 can define a separate, second insert airflow pathway 155. Additionally, the first compartment 260 can contain vaporizable material 102 and be positioned between the second and third compartments 262 and 263.

In some embodiments, at least part of the housing 152 can be made out of a paper material and/or a thermally conductive material, such as a metal or aluminum foil. The thermally conductive housing 152 can assist with substantially and evenly heating the vaporizable material 102 within the inner chamber 153, such as contained in the first compartment 260. In some embodiments, at least part of the housing 152 is made out of a non-permeable membrane. Other materials and embodiments of the housing 152 are within the scope of this disclosure.

Terminology

When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present.

Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Terminology used herein is for the purpose of describing particular embodiments and implementations only and is not intended to be limiting. For example, as used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items and may be abbreviated as “/”.

In the descriptions above and in the claims, phrases such as “at least one of” or “one or more of” may occur followed by a conjunctive list of elements or features. The term “and/or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;” “one or more of A and B;” and “A and/or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;” “one or more of A, B, and C;” and “A, B, and/or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” Use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

Spatially relative terms, such as “forward”, “rearward”, “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

Although the terms “first” and “second” may be used herein to describe various features/elements (including steps), these features/elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed below could be termed a second feature/element, and similarly, a second feature/element discussed below could be termed a first feature/element without departing from the teachings provided herein.

As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/−0.1% of the stated value (or range of values), +/−1% of the stated value (or range of values), +/−2% of the stated value (or range of values), +/−5% of the stated value (or range of values), +/−10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, if the value “10” is disclosed, then “about 10” is also disclosed. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. It is also understood that when a value is disclosed that “less than or equal to” the value, “greater than or equal to the value” and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value “X” is disclosed the “less than or equal to X” as well as “greater than or equal to X” (e.g., where X is a numerical value) is also disclosed. It is also understood that the throughout the application, data is provided in a number of different formats, and that this data, represents endpoints and starting points, and ranges for any combination of the data points. For example, if a particular data point “10” and a particular data point “15” are disclosed, it is understood that greater than, greater than or equal to, less than, less than or equal to, and equal to 10 and 15 are considered disclosed as well as between 10 and 15. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

Although various illustrative embodiments are described above, any of a number of changes may be made to various embodiments without departing from the teachings herein. For example, the order in which various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments one or more method steps may be skipped altogether. Optional features of various device and system embodiments may be included in some embodiments and not in others. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the claims.

One or more aspects or features of the subject matter described herein can be realized in digital electronic circuitry, integrated circuitry, specially designed application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) computer hardware, firmware, software, and/or combinations thereof. These various aspects or features can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device. The programmable system or computing system may include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

These computer programs, which can also be referred to programs, software, software applications, applications, components, or code, include machine instructions for a programmable processor, and can be implemented in a high-level procedural language, an object-oriented programming language, a functional programming language, a logical programming language, and/or in assembly/machine language. As used herein, the term “machine-readable medium” refers to any computer program product, apparatus and/or device, such as for example magnetic discs, optical disks, memory, and Programmable Logic Devices (PLDs), used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor. The machine-readable medium can store such machine instructions non-transitorily, such as for example as would a non-transient solid-state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium can alternatively or additionally store such machine instructions in a transient manner, such as for example, as would a processor cache or other random access memory associated with one or more physical processor cores.

The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. As mentioned, other embodiments may be utilized and derived there from, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is, in fact, disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. 

1. A system for generating an inhalable aerosol, the system comprising: an insert, comprising: a housing defining an inner chamber, the inner chamber comprising: a first compartment configured to contain a non-liquid vaporizable material, the non-liquid vaporizable material forming a part of the inhalable aerosol as a result of being heated; and a second compartment that is separate from the first compartment of the inner chamber and defines a first insert airflow pathway, the second compartment configured to allow formation of the inhalable aerosol therealong and delivery of the inhalable aerosol through the outlet for inhalation by a user; and a vaporizer body comprising: a receptacle configured to receive the insert; and a device airflow pathway that extends into the receptacle between the insert and a side wall of the receptacle, the device airflow pathway being upstream from the first insert airflow pathway; wherein the system further comprises a heating element configured to heat the non-liquid vaporizable material when the insert is positioned in the receptacle to generate the inhalable aerosol.
 2. The system of claim 1, further comprising an outlet positioned along a mouthpiece of the insert.
 3. The system of claim 2, further comprising an inlet positioned along a first end of the insert, the first end being opposed to a second end including the mouthpiece.
 4. The system of claim 1, wherein the first compartment and the second compartment extend approximately parallel to each other.
 5. The system of claim 1, wherein the inner chamber further includes a third compartment configured to contain additional non-liquid vaporizable material, the second compartment positioned between the first compartment and the third compartment.
 6. The system of claim 1, wherein the inner chamber further includes a third compartment configured to define a second insert airflow pathway that is downstream from the device airflow pathway, the first compartment positioned between the second compartment and the third compartment.
 7. The system of claim 1, wherein the housing comprises aluminum foil.
 8. (canceled)
 9. The system of claim 1, wherein the housing comprises a paper material.
 10. The system of claim 1, wherein the non-liquid vaporizable material comprises a plant material and/or a plant material based product.
 11. The system of claim 1, wherein the non-liquid vaporizable material comprises a tobacco leaf and/or a reconstituted tobacco.
 12. An insert configured to be inserted into a compartment of a vaporizer device, the insert comprising: a housing defining an inner chamber, the inner chamber comprising: a first compartment configured to contain a non-liquid vaporizable material, the non-liquid vaporizable material forming a part of the inhalable aerosol as a result of being heated; and a second compartment that is separate from the first compartment of the inner chamber and defines a first insert airflow pathway, the second compartment extending between an inlet and an outlet of the housing and configured to allow formation of the inhalable aerosol therealong and delivery of the inhalable aerosol through the outlet for inhalation by a user.
 13. The insert of claim 12, wherein the outlet is positioned along a mouthpiece of the insert.
 14. The insert of claim 13, wherein the inlet is positioned along a first end of the insert, the first end being opposed to a second end including the mouthpiece.
 15. The insert of claim 12, wherein the first compartment and the second compartment extend approximately parallel to each other.
 16. The insert of claim 12, wherein the inner chamber further includes a third compartment configured to contain the non-liquid vaporizable material, the second compartment positioned between the first compartment and the third compartment.
 17. The insert of claim 12, wherein the inner chamber further includes a third compartment configured to define a second insert airflow pathway that is downstream from the device airflow pathway, the first compartment positioned between the second compartment and the third compartment.
 18. The insert of claim 12, wherein the housing comprises aluminum foil.
 19. (canceled)
 20. The insert of claim 12, wherein the housing comprises a paper material.
 21. The insert of claim 12, wherein the non-liquid vaporizable material comprises a plant material and/or a plant material based product.
 22. The insert of claim 12, wherein the non-liquid vaporizable material comprises a tobacco leaf and/or a reconstituted tobacco. 23.-32. (canceled) 